Clean driving pleasure with E

Low-voltage electric drive system consisting of a highly efficient brushless direct-current (BLDC) motor and an electronic controller. It is designed to operate in variety of electric vehicles in particular for light electric vehicles, light AT quadricycles, and electric motorcycles.

The motor includes high energy permanent magnets and low-loss materials to achieve motor efficiency over 90%. The motor speed torque characteristics are suitable for direct-belt drive applications and for various transmission solutions.

Thanks to the typical IPM motor configuration, this electric motor has excellent torque and power density. As it is a brushless variant, it requires no maintenance during its entire lifetime of typically over 20,000 hours.

The electronic controller is programmed to drive the electric motor in the efficient, field-oriented vector control and will function in various operation modes such as normal drive, ECO mode, booster mode, and regenerative braking. Other useful functions (temperature, current, undervoltage/undervoltage protection) are fully programmable. The controller is CAN-enabled.

AC induction motors and ECU

MAHLE’s AC induction motors are four-pole motors with an aluminum cage rotor and three-phase winding on the stator. The stator and rotor laminations are specially designed for low-voltage applications used in different electric vehicles. Induction motors offer excellent dynamics over a wide speed range and very low noise operation. The motors are powered and controlled by an AC ECU, which converts the DC voltage to three-phase voltage at the required amplitude and frequency. Thanks to additional settings of the ECU parameters, it can be well adjusted to the requirements of various installations and applications.

Advanced diagnostics and communications are provided through the CANOpen bus. AC induction motors with corresponding ECUs represent the best traction solution for battery-powered electric vehicles, such as golf carts, airport luggage carts, small electric cars, and other applications. Several motors are available in higher IP protections. AC induction motor drives are available in both low- (24–80V) and high-voltage ranges (200–450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.

BLPM motors and ECU

MAHLE brushless permanent magnet motors with ferrite or rare earth magnets on the rotor combine high performance and reliability with a simple design, resulting in  optimal price-performance ratios. The multipole motors offer high efficiency (> 90%) over a wide speed range and high torque at low speeds. Using a special motor design, the cogging torque level is extremely low. The motor has no commutator and brushes, nor slots and windings on the rotor. This ensures very low acoustic noise and torque ripple. This type of motor is powered and controlled by separate or built-in BLPM ECUs, whose basic function is to provide the electronic commutation to stator phases based on the rotor position (detected by an integrated absolute encoder).

Communication from/to external electronic devices is done by using analog signals, digital I/O, PWM signals, or CANOpen communication. Integrating the ECU in the motor housing creates a single, compact drive unit. Typical applications for such motor versions are steering applications and small traction motor drives. BLPM drive systems are available in both low- (12–80V) and high-voltage ranges (200–450V). Most comply with the automotive industry ECE R10-5 standards for EMC emissions and immunity.

Motors for electric brake boosters (EBB)

For brake boosting with an electric motor instead of a vacuum, MAHLE offers a 12 V mounted SPM BLDC motor. The motor is specifically designed for the needs of an electric brake booster (EBB). The scalable torque output makes it possible to meet individual customer requirements while featuring a robust design and high power density.